Pioneer 1200, Maintenance Service Manual

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STEERING AND FRONT SUSPENSION Front Suspension Components
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 7-15
7
NOTE: If the bushings are replaced, ream new bushings to 0.750-.752 of an inch (19.05-19.10 mm) in
diameter. The reamer should be long enough to ream both bushings from one direction.
4. Install the spindle assembly (20) onto the A-arm (13) (Figure 7-29, Page 7-16).
5. Install the thrust washer (32), wave washer (33) and kingpin (21).
6. Install the washer (36) and a new lock nut (22). Tighten to 18 ft-lb (24.4 N·m).
7. Insert the ball joint (23) into the spindle assembly (Figure 7-20, Page 7-11).
8. Install the lock nut (24) and tighten to 40 ft-lb (54.2 N·m).
9. Install a new cotter pin (18) and bend it to secure it to the ball joint.
10. Use a grease gun and apply grease to the grease fitting (17) in the A-arm (13) (Figure 7-29, Page 7-16).
See Lubrication on page 7-12.
11. Install the brake cluster. See Front Brake Cluster Assembly Installation, Section 6, Page 6-17.
12. Install the wheel and tighten the lug nuts, using a crisscross pattern, to 55 ft-lb (74.6 N·m).
13. Repeat steps 1 through 12 for the opposite front wheel if necessary.
14. Check toe-in adjustment and make adjustments if necessary. See Toe-in Adjustment on page 7-13.
A-ARM REMOVAL
1. Remove the front brake cluster. See Front Brake Cluster Assembly Removal, Section 6, Page 6-17.
2. Remove cotter pin (18), nut (24) and ball joint from the spindle assembly (Figure 7-20, Page 7-11).
3. Remove the nut (22), washer (36) and kingpin (21) (Figure 7-29, Page 7-16).
4. Remove the thrust washer (32).
Figure 7-28 Rest Brake Cluster on A-arm